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Save This Manual Keep this manual for the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.
1. Keep work area clean and well lit. 3. Keep children and bystanders
Cluttered or dark areas invite accidents. away while operating a power tool.
Distractions can cause you to lose control.
2. Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or fumes.
Safety
2. Avoid body contact with grounded surfaces 5. When operating a power tool outdoors,
such as pipes, radiators, ranges and use an extension cord suitable for
refrigerators. There is an increased risk of outdoor use. Use of a cord suitable for outdoor
electric shock if your body is grounded. use reduces the risk of electric shock.
3. Do not expose power tools to rain or wet 6. If operating a power tool in a damp location
conditions. Water entering a power tool is unavoidable, use a Ground Fault Circuit
will increase the risk of electric shock. Interrupter (GFCI) protected supply.
Use of a GFCI reduces the risk of electric shock.
Personal safety
1. Stay alert, watch what you are doing 4. Do not overreach. Keep proper footing and
and use common sense when operating balance at all times. This enables better control
Setup
a power tool. Do not use a power of the power tool in unexpected situations.
tool while you are tired or under the
influence of drugs, alcohol or medication. 5. Dress properly. Do not wear loose clothing or
A moment of inattention while operating power jewelry. Keep your hair, clothing and gloves
tools may result in serious personal injury. away from moving parts. Loose clothes, jewelry
or long hair can be caught in moving parts.
2. Use personal protective equipment.
Always wear eye protection. Safety equipment 6. If devices are provided for the connection of
such as dust mask, non-skid safety shoes, dust extraction and collection facilities, ensure
hard hat, or hearing protection used for appropriate these are connected and properly used. Use of
conditions will reduce personal injuries. these devices can reduce dust‑related hazards.
3. Prevent unintentional starting. 7. Only use safety equipment that has been
Ensure the Trigger is in the off‑position before approved by an appropriate standards agency.
connecting to power source, picking up or Unapproved safety equipment may not provide
Operation
carrying the tool. Carrying power tools with adequate protection. Eye protection must be
your finger on the Trigger or energizing power ANSI‑approved and breathing protection
tools that have the Trigger on invites accidents. must be NIOSH‑approved for the
specific hazards in the work area.
1. Wear ear protectors. 15. People with pacemakers should consult their
Exposure to noise can cause hearing loss. physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
2. Use auxiliary handles supplied with the tool. pacemaker interference or pacemaker failure.
Loss of control can cause personal injury. In addition, people with pacemakers should:
• Avoid operating alone.
3. Hold power tools by insulated gripping surfaces
• Properly maintain and inspect to avoid
when performing an operation where the cutting
electrical shock.
tool may contact hidden wiring or its own cord.
• Properly ground power cord. Ground Fault Circuit
Contact with a ″live″ wire will make exposed metal
Interrupter (GFCI) should also be implemented
parts of the tool ″live″ and shock the operator.
– it prevents sustained electrical shock.
4. Keep clear of moving parts.
16. WARNING: Some dust created by power sanding,
5. Unplug before inspecting, removing or sawing, grinding, drilling, and other construction
activities, contains chemicals known to the State
Setup
Harbor Freight Tools for a replacement. specially designed to filter out microscopic particles.
(California Health & Safety Code § 25249.5, et seq.)
10. Avoid unintentional starting.
Prepare to begin work before turning on the tool. 17. WARNING: The cord of this product contains
lead, a chemical known to the State of California
11. Do not lay the tool down until it has come to to cause cancer, and birth defects or other
a complete stop. Moving parts can grab the reproductive harm. Wash hands after handling.
surface and pull the tool out of your control. (California Health & Safety Code § 25249.5, et seq.)
12. When using a handheld power tool, 18. The warnings, precautions, and instructions
maintain a firm grip on the tool discussed in this instruction manual cannot cover all
with both hands to resist starting torque. possible conditions and situations that may occur.
It must be understood by the operator that
13. Do not leave the tool unattended when it is plugged common sense and caution are factors
into an electrical outlet. Turn off the tool, and which cannot be built into this product,
unplug it from its electrical outlet before leaving. but must be supplied by the operator.
Maintenance
1. Anyone using vibrating tools regularly or for 2. Do not smoke during use. Nicotine reduces
Safety
an extended period should first be examined the blood supply to the hands and fingers,
by a doctor and then have regular medical increasing the risk of vibration-related injury.
check-ups to ensure medical problems are not
being caused or worsened from use. Pregnant 3. Wear suitable gloves to reduce
women or people who have impaired blood the vibration effects on the user.
circulation to the hand, past hand injuries,
4. Use tools with the lowest vibration
nervous system disorders, diabetes, or
when there is a choice.
Raynaud’s Disease should not use this tool.
If you feel any symptoms related to 5. Include vibration-free periods each day of work.
vibration (such as tingling, numbness,
and white or blue fingers), seek medical 6. Let the tool do the work.
advice as soon as possible.
7. To reduce vibration, maintain the tool as
explained in this manual. If any abnormal
vibration occurs, stop use immediately.
Setup
SAVE THESE INSTRUCTIONS.
Operation
Maintenance
Check with a qualified electrician if you are in doubt as to whether the outlet
is properly grounded. Do not modify the power cord plug provided with the
tool. Never remove the grounding prong from the plug. Do not use the tool if the power
cord or plug is damaged. If damaged, have it repaired by a service facility before use. If
the plug will not fit the outlet, have a proper outlet installed by a qualified electrician.
Safety
you must use a heavier gauge extension cord. 8. Protect the extension cords from sharp objects,
Using extension cords with inadequately sized wire excessive heat, and damp or wet areas.
causes a serious drop in voltage, resulting in loss of
power and possible tool damage. (See Table A.) Table A: RECOMMENDED MINIMUM WIRE
GAUGE FOR EXTENSION CORDS* (120/240 VOLT)
3. The smaller the gauge number of the wire, the EXTENSION CORD
NAMEPLATE
greater the capacity of the cord. For example,
a 14 gauge cord can carry a higher current AMPERES LENGTH
than a 16 gauge cord. (See Table A.) (at full load) 25´ 50´ 75´ 100´ 150´
0 – 2.0 18 18 18 18 16
4. When using more than one extension cord
to make up the total length, make sure 2.1 – 3.4 18 18 18 16 14
each cord contains at least the minimum 3.5 – 5.0 18 18 16 14 12
wire size required. (See Table A.)
5.1 – 7.0 18 16 14 12 12
Setup
5. If you are using one extension cord for more 7.1 – 12.0 18 14 12 10 -
than one tool, add the nameplate amperes 12.1 – 16.0 14 12 10 - -
and use the sum to determine the required
minimum cord size. (See Table A.) 16.1 – 20.0 12 10 - - -
* Based on limiting the line voltage drop to five volts at
6. If you are using an extension cord outdoors, make 150% of the rated amperes.
sure it is marked with the suffix “W-A” (“W” in
Canada) to indicate it is acceptable for outdoor use.
Symbology
WARNING marking concerning Risk
Double Insulated of Eye Injury. Wear ANSI‑approved
Operation
safety goggles with side shields.
Canadian Standards Association
Read the manual before
set-up and/or use.
Underwriters Laboratories, Inc.
WARNING marking
concerning Risk of Fire.
V Volts Do not cover ventilation ducts.
Keep flammable objects away.
~ Alternating Current
WARNING marking concerning
Risk of Electric Shock.
Properly connect power cord
A Amperes to appropriate outlet.
WARNING marking concerning
n0 xxxx/min. No Load Revolutions per Minute (RPM) Risk of Hearing Loss.
Maintenance
E252823
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
Setup
manual including all text under subheadings therein before set up or use of this product.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Make sure that the Trigger is in the off-
position and unplug the tool from its electrical outlet before performing any procedure in this section.
Assembly
The only assembly required for the Breaker Gear Cover
Hammer is the installing of the Secondary
Operation
Steel Bushing
Bolt
Figure A
Maintenance
Safety
Main Handle
Secondary Handle
Setup
Operation
Maintenance
Lock
Lever
Figure B
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual
including all text under subheadings therein before set up or use of this product.
Tool Set Up
Safety
1. Pull the Lock Lever to the side, just 2. Insert Chisel with the Flat Notch facing the
Setup
Flat
Notch
Figure D
2
3. Slide the Chisel in as far as it will go.
Operation
Play
Figure E
Note: Flat Notch on Collar-less Chisel
must face the Lock Lever. 5. When the Chisel is installed, there will be
approximately 1-3/4" of play along the Flat Notch
of the shank. See Figure E. Physically check
that the Chisel is secure before operating.
Safety
3
1
Retaining
Ring
Figure F
Setup
3. Slide the Chisel in as far as it will go.
Figure G
Operation
Figure H
Safety
Keep children and animals well clear of the work area.
1. Check Chisel for dullness, cracks, or other damage. 7. Push the tip forcibly down to begin striking material.
NOTICE: Running tool with no load or “empty
blows” will damage the Breaker Hammer.
CAUTION! Once activated, do not press,
bear down, or thrust forcibly against the work
surface. Allow the Breaker Hammer’s own
weight to supply the needed force.
Note: If the Breaker Hammer has not been used for
CAUTION! Dull tipped chisels can cause unnecessary
a long time or is being used in low temperatures,
chisel movement, resulting in tool wear and
the tool may require 3-5 minutes to warm up.
possible injury. Use only sharp tipped chisels.
2. Clearly mark the work area. NOTE: Carbon Brushes will wear during use.
The Breaker Hammer will stop working if the
Setup
3. Make sure that the Trigger is in Brushes are worn. This does NOT mean Breaker
the off‑position, then plug the tool into an Hammer is malfunctioning or broken, only that
outlet on a circuit rated to 20 amps. the worn Brushes will need to be replaced with
4. Set the bit against the work area. the included Brushes by a qualified technician.
CAUTION! Keep power cord away 8. When work is complete, release the Trigger.
from moving machines. The Trigger is spring-loaded and will return
5. Place one hand on the Side Handle and to the off position automatically.
the other hand around the Main Handle. 9. To prevent accidents, turn off the tool and
6. Press down on the Trigger. disconnect its power supply after use.
Note: Trigger does not lock. Keep pressure 10. Clean, then store the tool indoors
on the Trigger to keep running the tool. out of children’s reach.
Operation
Maintenance
NOTE: The Breaker Hammer will cease operation once Carbon Brushes are worn.
Check Brushes every 100 hours and replace when necessary.
1. Remove the Fan Cover (10) by loosening the 5. Insert new Carbon Brush.
Bolt (12) and Flat Washer (11). See Figure I. 6. Replace Carbon Brush Cap and slide
Operation
2. Slide Fan Cover off of Housing (1). Fan Cover back over Housing.
3. Remove Brush Cap (5) from Housing. 7. Replace Bolts and Flat Washers
4. Remove old Carbon Brush (6). until securely fastened.
Brush Cap (5)
Carbon
Brush (6)
Carbon Brush
Housing (1)
Holder (7)
Insulation
Washer (8) Fan Cover
(10) Flat Washer (11)
Bolt (12)
Maintenance
Figure I
1. Loosen the four Socket Head Bolts (59) 4. Fill each of the 4 grooves inside the
and Washers (4) that connect the Aluminum Housing with 0.5 ounces of
Safety
Aluminum Housing (60) to the Housing (8). synthetic high-temperature grease.
Disassemble the Aluminum Housing,
Ram (57) and Piston (55). See Figure J. 5. Slide the Ram back into the Cylinder Case
and fill it with 0.5 ounces of tool oil.
2. Clean the Aluminum Housing, Piston and
Ram thoroughly, inside and out. 6. Carefully slide the Piston into the Ram, making sure
that the O-Ring stays in place and is not damaged.
3. Check the condition of the O-Ring (56).
If the outside diameter (OD) of the O-Ring is 7. Use the four Socket Head Bolts to
less than the Piston’s OD, replace the O-Ring. connect the Aluminum Housing to the
Housing and tighten securely.
Aluminum
Housing (60)
Setup
Ram (57)
Socket Head
Bolt (59)
Washer (4)
Piston (55)
Housing (1)
Operation
Figure J
Maintenance
Safety
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
Setup
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
Operation
Maintenance
Parts List
Part Description Qty Part Description Qty
Safety
111 110 79 78 77 76 73
Safety
104 105 7271
70 69
103 68 67
10 2 75 66 65
108
74
10 1
6 63 61
62 61A
60
Setup
58 57 2 3
59 4 5
56 55 4
54 6
52
49 48 7
1 00 50 47 8
99 53 51 1 10
90 91 80 9
82 12
98 43 22A40 11 12
42
Operation
97 96 41
89 95 44 46
17 93 94 45
11 81
90 40 13
39 22 14
92 86 38 4
23 15
88 37
91 89 24
36 25 18
90
29 26 19
27 20
Maintenance
4 28
26 109
35
14A
30 21
31A
31
34